Multi-shaft gas turbine engine

ABSTRACT

A gas turbine engine is disclosed with a first spool having a first turbine connected to a first compressor through a first rotatable shaft; a second spool having a second turbine connected to a second compressor through a second rotatable shaft; and a gearbox having a power input port coupled to each of the first and second shafts and a power output port connected to a third shaft, wherein the rotational speed of the third shaft is lower than the rotational speed of each of the first and second shafts.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser.No. 61/774,537, entitled “Multi-Shaft Gas Turbine Engine,” filed Mar. 7,2013, which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a multi-shaft gas turbine engine, andmore particularly to a multi-shaft gas turbine engine having two or moreturbines coupled to at least one gearbox to improve the efficiency ofone or more power devices coupled thereto.

BACKGROUND

Gas turbine engine designers continuously work to improve engineefficiency, to reduce operating costs of the engine, and to reducespecific exhaust gas emissions such as NOx, CO2, CO, unburnedhydrocarbons, and particulate matter. The specific fuel consumption(SFC) of an engine is inversely proportional to the overall thermalefficiency of the engine, thus, as the SFC decreases the fuel efficiencyof the engine increases. Furthermore, specific exhaust gas emissionstypically decrease as the engine becomes more efficient. The thermalefficiency of the engine is a function of component efficiencies, cyclepressure ratio and turbine inlet temperature. Component efficiencies ofpower devices such as fans, turboprops, electric generators and the likeare a function of their rotational speed at a particular operatingcondition of the gas turbine engine. Gas turbine power systems remain anarea of interest. Some existing gas turbine power systems have variousshortcomings, drawbacks, and disadvantages relative to certainapplications. Accordingly, there remains a need for furthercontributions in this area of technology.

SUMMARY

One embodiment of the present invention is a unique gas turbine enginepropulsion system. Another embodiment includes a gas turbine enginepower system having a gearbox for driving a power device. Otherembodiments include unique apparatuses, systems, devices, hardware,methods, and combinations for gas turbine engine power systems. Furtherembodiments, forms, features, aspects, benefits, and advantages of thepresent application shall become apparent from the following descriptionand drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawingswherein like reference numerals refer to like parts throughout theseveral views, and wherein:

FIG. 1 is a schematic cross-sectional view of a conventional multi-spoolgas turbine engine;

FIG. 2 is a schematic cross-sectional view of a multi-spool gas turbineengine according to one embodiment of the present disclosure;

FIG. 3 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure;

FIG. 4 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure;

FIG. 5 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure;

FIG. 6 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure;

FIG. 7 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure;

FIG. 8 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure; and

FIG. 9 is a schematic cross-sectional view of a multi-spool gas turbineengine according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

For purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings, and specific language will be used to describe the same.It will nonetheless be understood that no limitation of the scope of theinvention is intended by the illustration and description of certainembodiments of the invention. In addition, any alterations and/ormodifications of the illustrated and/or described embodiment(s) arecontemplated as being within the scope of the present invention.Further, any other applications of the principles of the invention, asillustrated and/or described herein, as would normally occur to oneskilled in the art to which the invention pertains, are contemplated asbeing within the scope of the present invention.

Referring to FIG. 1, a schematic view of a conventional multi-shaft gasturbine engine 10 is depicted. While the gas turbine engine 10 isillustrated with three spools (i.e. one shaft connecting a turbine and acompressor for each of the high pressure, intermediate pressure and lowpressure stages), it should be understood that the present disclosure isnot limited to a three spool engine configuration and as such may beused in two spool engines for both thrust producing and power generationconfigurations such as electric generation and fluid pumpingapplications. It should also be understood that the present disclosurecontemplates any engine configuration having a gearbox and power device.The gas turbine engine 10 will be described generally, howeversignificant details regarding general gas turbine engine function andoperation will not be presented herein as it is believed that the theoryof operation and general parameters of gas turbine engines are wellknown to those of ordinary skill in the art. It should be understoodthat any form of gas turbine engine is contemplated by the presentdisclosure, including those engines with variable geometryturbomachinery, variable exhaust nozzles, and other movable structure.

The gas turbine engine 10 includes an inlet section 12, a compressorsection 14, a combustor section 16, a turbine section 18, and an exhaustsection 20. In operation, air is drawn in through the inlet 12 which caninclude a fan inlet for a turbofan engine and a compressor inlet andcompressed to a high pressure relative to ambient pressure in thecompressor section 14. The air is mixed with fuel in the combustorsection 16 wherein the fuel/air mixture burns and produces a hightemperature and high pressure working fluid from which the turbinesection 18 extracts power. The turbine section 18 is mechanicallycoupled to the compressor section 14 and can also be coupled to a powerdevice 15. The power device 15 can include a fan for a bypass turbofanengine, a propeller for a turboprop engine, an electric generator, acompressor, and a pump or the like. In this configuration a compressorsection 14 includes a high pressure compressor 22, an intermediatecompressor 24, and a low pressure compressor 26 driven by a highpressure turbine 28, an intermediate turbine 30, and a low pressureturbine 32, respectively. A high pressure shaft 34, an intermediatepressure shaft 36, and a low pressure shaft 38 mechanically connect therespective turbine and compressor sections. The shafts 34, 36, 38 rotateabout a centerline axis 40 that extends axially along the longitudinalaxis of the engine 10, such that as the turbine section 18 rotates dueto the forces generated by the high pressure working fluid, thecompressor section 14 is rotatingly driven by the turbine section 18 toproduce compressed air. A portion of the power extracted from theturbine section 18 can be utilized to drive the power device 15.

The present disclosure provides for a gas turbine engine in variousforms having at least two turbines coupled to one or more gearboxes toprovide power thereto. When the term “gearbox” is used in thisdisclosure it should be understood that it is used generically as adevice to increase torque output while reducing the rotational speed ofone or more output shafts relative to one or more prime mover inputshafts. The one or more output shafts of a gearbox can rotate at aslower rate than the input shafts, and this reduction in speed willproduce a mechanical advantage causing an increase in torque. Aparticular type of gearbox or design of gearbox is not required forimplementation of this disclosure. The gearbox may include hydraulicmeans, electric means, one or more clutches, transmission means tocontrol variable gear ratios and other features useful for anoperationally viable gearbox that can be coupled to a gas turbineengine. Also, it should be noted that the terms “connect” and “couple”can be used interchangeably to describe means for mechanical drivingand/or causing movement by and between shafts, gears, gearboxes,turbomachinery (including turbines and compressors) and other powerdevices. A controller, not shown in the drawings, can be used to controlthe output speeds and torque levels of the gearbox output shafts aswould be known by one skilled in the art.

One or more gearboxes can be positioned in the gas turbine engine toimprove component efficiencies of the turbomachinery (i.e. compressorsand turbines) and a power device. The efficiency improvement comesthrough control of rotational speeds of the turbomachinery and powerdevices such that individual turbines, compressors and power devicesoperate as close as possible to ideal design efficiency across anoperating region of the gas turbine engine. Each gearbox can be operablefor receiving power from one or more turbines and transmitting thatpower to a power device. In general a power device will operate at ahigher efficiency when running at a different rotational speed than thatof the turbines providing power to the power device. The power devicecan include, but is not limited to one or more turbofans, turboprops,electric generators, motor-generators, pusher props, unducted fans andthe like. Each gearbox can include a power input port constructed toreceive one or more input shafts from corresponding one or more turbinesand/or power from the output of another gearbox. Each gearbox can alsoinclude a power output port that can be connected to one or more outputshafts for delivering power to a power device and/or another gearbox.Each gearbox operates to transmit power from relatively high-speed inputshaft(s) to one or more output shafts at a reduced speed through a gearreduction system.

In one form, a gearbox can be configured to transmit power directly fromone turbine to one or more power devices through gear means operable forindependently controlling the output torques and rotational speeds ofthe one or more output shafts. In another form, a gearbox can be coupledto a plurality of turbines such that the power from the turbines can becombined and then separated and transmitted to independent power devicesthrough gear means operable for delivering a torque output and a speedoutput as desired to each independently controlled output shaft. Inanother form, a gearbox can be configured as a “pass through” gearboxwherein a plurality of power input shafts are connected to independentgear trains within the gearbox such that each power output shaft isindependently and directly connected to one corresponding power inputshaft.

Referring now to FIG. 2, a gearbox 50 is positioned in the gas turbineengine 10. The gearbox 50 can include a power input port 52 and a poweroutlet port 54. The power input port 52 is constructed to receive one ormore input shafts to deliver power from one or more turbines of the gasturbine engine 10. The power outlet port 54 is constructed to couple oneor more output shafts 56 to one or more power devices 15. Power devices15 can include, but are not limited to turbofans, turboprops, electricgenerators, motor-generators, pusher props, and unducted fans. A lowpressure turbine 32 can be coupled to a low pressure compressor 26through a low pressure rotatable shaft 38. The low pressure turbine 32can also be coupled to the power input port 52 of the gearbox 50 suchthat power in excess of that required to drive the low pressurecompressor 26 can be delivered to the gearbox 50. An intermediatepressure turbine 30 can be coupled to an intermediate pressurecompressor 24 through an intermediate pressure rotatable shaft 36. Theintermediate pressure turbine 30 can also be coupled to the power inputport 52 of the gearbox 50 such that power in excess of that required todrive the intermediate pressure compressor 24 can be delivered to thegearbox 50. A high pressure turbine 28 can be coupled to a high pressurecompressor 22 through a rotatable shaft 34. The high pressure turbine 28can also be coupled to the power input port 52 of the gearbox 50 suchthat power in excess of that required to drive the high pressurecompressor 22 can be delivered to the gearbox 50.

The gearbox 50 can be constructed to receive power from each independentshaft through a power inlet port 52. In one aspect of this disclosure,it is contemplated that some operating conditions of the gas turbineengine may require all of the power from one or more of the turbines 28,30, 32 to be delivered to their respective one or more compressors 22,24, 26 such that power input into the gearbox 50 comes from less thanall of the turbines coupled to the gearbox 50. In this form, the gearbox50 can receive and combine the power from each of the three shafts 34,36, 38 and transmit the power through gear means to the output shaft 56.The output shaft 56 couples the power device 15 to the gearbox 50through the power output port 54. The power output shaft 56 can becontrolled by a gearbox controller (not shown) to drive the power device15 to as close to peak efficiency as possible. In this manner, power istransmitted to the power device 15 such that thrust, fluid compressionand/or electrical power may be generated with the power device 15 at ahigh efficiency. In this exemplary configuration the gearbox 50 ispositioned axially forward of the compressor section 14, but it shouldbe understood that the gearbox 50 can be positioned in any desiredlocation and still fall under the teachings of this disclosure.

Referring now to FIG. 3, another embodiment of the gas turbine engine 10is shown. In this configuration, the gas turbine engine 10 includes ahigh pressure turbine 28 coupled to a high pressure compressor 22through a high pressure shaft 34. An intermediate turbine 30 can becoupled to both an intermediate compressor 24 and a power input port 52of a gearbox 50. A low pressure turbine 32 can be coupled to the powerinput port 52 of the gearbox 50. A power output port 54 of the gearbox50 can be coupled to a power device 15 through two power output shafts60 and 62. In this example, by way of illustration and not limitation,the power device 15 includes a forward propeller 17 and an aft propeller19. The forward propeller 17 can be driven by the low pressure turbine32 through the gearbox 50 and the aft propeller 19 can be driven bypower from the intermediate turbine 30 through the gearbox 50. In thisexemplary configuration the gearbox 50 is positioned axially forward ofthe compressor section 14 and the power device 15 is in the form of apair of propellers, but it should be understood that the gearbox 50 canbe positioned in any desired location and the power device 15 can be inother forms and still fall under the teachings of this disclosure.

Referring now to FIG. 4, yet another embodiment of the gas turbineengine 10 is shown. In this configuration the gas turbine engine 10includes a high pressure turbine 28 coupled to a high pressurecompressor 22 through a high pressure shaft 34. An intermediate turbine30 can be coupled to both an intermediate compressor 24 and a powerinput port 52 of a gearbox 50 through an intermediate shaft 36. A lowpressure turbine 32 can be coupled to a power input port 52 of thegearbox 50. The power input port 52 of the gearbox 50 can be coupled totwo independent turbines 30, 32 through the intermediate and lowpressure shafts 36, 38 respectively. The power output port 54 of thegearbox 50 can be coupled to a power device 15 through two output shafts60 and 62. In this example, by way of illustration and not limitation,the power device 15 includes a forward propeller 17 and an aft propeller19. The forward propeller 17 can be driven by power from theintermediate turbine 32 through the gearbox 50 and the aft propeller 19can be driven by power from the low pressure turbine 32 through thegearbox 50. In this exemplary configuration the gearbox is positionedforward of the compressor section 14 and the power device 15 is in theform of a forward propeller 15 and an aft propeller 19, but it should beunderstood that the gearbox 50 can be positioned in any desired locationand the power device 15 can be in other forms and still fall under theteachings of this disclosure.

Referring now to FIG. 5, yet another embodiment of the gas turbineengine 10 is shown. In this configuration the gas turbine engine 10includes a high pressure turbine 28 coupled to a high pressurecompressor 22 through a high pressure shaft 34. The high pressureturbine 28 can also be coupled to a power input port 52 of a gearbox 50through the high pressure shaft 34. A low pressure turbine 32 can becoupled directly to the power input port 52 of the gearbox 50 through alow pressure shaft 38. Power from the low pressure turbine shaft 38 andthe high pressure turbine shaft 34 is delivered to the gearbox 50 andtransmitted to a power device 15 through an output shaft 56 coupled to apower outlet port 54 of the gearbox 50. In this exemplary configurationthe gearbox 50 is positioned aft of the turbine section 18 and the powerdevice 15 is in the form of a pusher propeller 21, but it should beunderstood that the gearbox 50 can be positioned in any desired locationand the power device 15 can be in other forms and still fall under theteachings of this disclosure.

Referring now to FIG. 6, yet another embodiment the gas turbine engine10 is shown. In this configuration, the gas turbine engine 10 includes ahigh pressure turbine 28 coupled to a high pressure compressor 22through a high pressure shaft 34. The high pressure turbine 28 can alsobe coupled to a power input port 72 of a second gearbox 70 through thehigh pressure shaft 34. A low pressure turbine 32 can be coupled to apower input port 52 of a first gearbox 50 through a low pressure shaft38. An output shaft 76 of the second gearbox 70 can be coupled to thelow pressure shaft 38 such that power from the output shaft 76 of thesecond gearbox 70 can be combined with the power output of the lowpressure turbine 38 and delivered to the first gearbox 50. The combinedpower of the low pressure turbine 32 and the output of the secondgearbox 70 can be transmitted through the first gear box 50 to the poweroutput port 54 of the first gearbox 50. An output shaft 56 can becoupled to the power output port 54 of the first gearbox 50 to drive apower device 15. In this exemplary configuration the first gearbox 50 ispositioned aft of the turbine section 18, the second gearbox 70 ispositioned axially forward of the first gearbox 50 and the power device15 is in the form of a pusher propeller 21, but it should be understoodthat the first gearbox 50 and the second gearbox 70 can be positioned inany desired location and the power device 15 can be in other forms andstill fall under the teachings of this disclosure.

Referring now to FIG. 7, yet another embodiment of the gas turbineengine 10 is shown. In this configuration, the gas turbine engine 10includes a high pressure turbine 28 coupled to a high pressurecompressor 22 through a high pressure shaft 34. The high pressureturbine 28 can also be coupled to a power input port 72 of a secondgearbox 70 through the high pressure shaft 34. A low pressure turbinecan be coupled to a power input port 52 of a first gearbox 50 through alow pressure shaft 38. A power output shaft 56 can be coupled to a poweroutput port 54 of the first gearbox 50. A power output shaft 76 of thesecond gearbox 70 can be coupled from the power outlet port 74 to theoutput shaft 56 of the first gearbox 50 such that power from the outputshaft 76 of the second gearbox 70 can be combined with the power outputof the first gearbox 50. The combined power output of the first andsecond gearboxes 50, 70 can be transmitted through the output shaft 56of the first gearbox 50 to drive the power device 15. In this exemplaryconfiguration the first gearbox 50 is positioned aft of the turbinesection 18, the second gearbox 70 is positioned axially forward of thefirst gearbox 50 and the power device 15 is in the form of a pusherpropeller 21, but it should be understood that the first gearbox 50 andthe second gearbox 70 can be positioned in any desired location and thepower device 15 can be in other forms and still fall under the teachingsof this disclosure.

Referring now to FIG. 8, yet another embodiment of the gas turbineengine 10 is shown. In this configuration, the gas turbine engine 10includes a high pressure turbine 28 coupled to a high pressurecompressor 22 through a high pressure shaft 34. The high pressureturbine 28 is also coupled to a power input port 72 of a second gearbox70 through the high pressure shaft 34. A low pressure turbine 32 can becoupled to a power input port 52 of a first gearbox 50 to provide powerthereto. An output shaft 76 can be coupled from an output port 74 of thesecond gearbox 70 to a power input port 52 of a first gearbox 50 suchthat power from the output shaft 76 of the second gearbox 70 can becombined with the power input from the low pressure turbine 32. Thecombined power of the low pressure turbine 32 and the output of thesecond gearbox 70 can be transmitted to a power device 15 through anoutput shaft 56 coupled to a power output port 54 of the second gearbox50. In this exemplary configuration the first gearbox 50 is positionedaft of the turbine section 18, the second gearbox 70 is positionedaxially forward of the first gearbox 50 and the power device 15 is inthe form of a pusher propeller 21, but it should be understood that thefirst gearbox 50 and the second gearbox 70 can be positioned in anydesired location and the power device 15 can be in other forms and stillfall under the teachings of this disclosure.

Referring now to FIG. 9, yet another embodiment of the gas turbineengine 10 is shown. In this configuration, the gas turbine engine 10includes a high pressure turbine 28 coupled to a high pressurecompressor 22 through a high pressure shaft 34. The high pressureturbine 28 is also coupled to a power input port 72 of a second gearbox70 through the high pressure shaft 34. An output shaft 76 of the secondgearbox 70 can be coupled to a power output port 74 of the secondgearbox 70. A low pressure turbine 32 can be coupled to the output shaft76 of the second gearbox 70 through a low pressure shaft 38. The outputshaft 76 carries power from the second gearbox 70 and the low pressureturbine 32 to a power input port 52 of first gearbox 50. The combinedpower of the low pressure turbine 32 and the second gearbox 70 can betransmitted through the first gearbox 50 to drive a power device 15through an output shaft 56 coupled to a power output port 54 of thesecond gearbox 50. In this exemplary configuration the first gearbox 50is positioned aft of the turbine section 18, the second gearbox 70 ispositioned axially forward of the first gearbox 50 and the power device15 is in the form of a pusher propeller 21, but it should be understoodthat the first gearbox 50 and the second gearbox 70 can be positioned inany desired location and the power device 15 can be in other forms andstill fall under the teachings of this disclosure.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment(s), but on the contrary, is intended to covervarious modifications and equivalent arrangements included within thespirit and scope of the appended claims, which scope is to be accordedthe broadest interpretation so as to encompass all such modificationsand equivalent structures as permitted under the law. Furthermore itshould be understood that while the use of the word preferable,preferably, or preferred in the description above indicates that featureso described may be more desirable, it nonetheless may not be necessaryand embodiment lacking the same may be contemplated as within the scopeof the invention, that scope being defined by the claims that follow. Inreading the claims it is intended that the words such as “a,” “an,” “atleast one” and “at least a portion” are used, there is no intention tolimit the claim to only one item unless specifically stated to thecontrary in the claim. Further, when the language “at least a portion”and/or “a portion” is used the item may include a portion and/or theentire item unless specifically stated to the contrary.

What is claimed is:
 1. A gas turbine engine comprising: a first spoolhaving a first turbine connected to a first compressor through a firstrotatable shaft; a second spool having a second turbine connected to asecond compressor through a second rotatable shaft; and a first gearboxhaving a power input port coupled to each of the first and second shaftsand a power output port connected to at least one output shaft, whereinthe rotational speed of the at least one output shaft is lower than therotational speed of each of the first and second shafts.
 2. The gasturbine engine of claim 1 further comprising: a third spool having athird turbine connected to a third compressor through a third rotatableshaft.
 3. The gas turbine engine of claim 2, wherein the third spool isconnected to the power input port of the first gearbox.
 4. The gasturbine engine of claim 2, wherein the rotational speed of the thirdturbine is independent from the first and second turbines.
 5. The gasturbine engine of claim 1 further comprising: a second gearbox having apower input port connected to one of the first and second spools and apower output port connected to the power input port of the firstgearbox.
 6. The gas turbine engine of claim 1 further comprising: asecond gearbox having a power input port connected to one of the firstand second spools and a power output port connected to the power outputport of the first gearbox.
 7. The gas turbine engine of claim 1 furthercomprising: a second gearbox having a power output port connected to oneof the power input port and the power output port of the first gearbox.8. The gas turbine engine of claim 7 further comprising: a third spoolhaving a third turbine connected to the second gearbox.
 9. The gasturbine engine of claim 1, wherein the power output port of the firstgearbox is connected to at least one of a ducted fan, an unducted fan, apropeller and an electric generator.
 10. A multi-shaft gas turbineengine comprising: a first gearbox having a power input port and a poweroutput port; a plurality of input shafts coupled to the power inputport; an output shaft coupled to the power output port of the firstgearbox; a separate turbine and a separate compressor connected to atleast one of the plurality of input shafts, each of the input shaftsoperable at different rotational speeds relative to one another; and apower device coupled to the output shaft of the first gearbox.
 11. Themulti-shaft gas turbine engine of claim 10, wherein the plurality ofinput shafts include three shafts each independently connected to threeseparate turbines.
 12. The multi-shaft gas turbine engine of claim 10further comprising: a second gearbox having a power input port connectedto at least one turbine and a power output port connected to the poweroutput port of the first gearbox.
 13. The multi-shaft gas turbine engineof claim 10 further comprising: a second gearbox having a power inputport connected to at least one turbine and a power output port connectedto the power input port of the first gearbox.
 14. The multi-shaft gasturbine engine of claim 10, wherein the power input port of the firstgearbox includes a connection to a power output port of a second gearboxand a connection to an independently coupled turbine.
 15. Themulti-shaft gas turbine engine of claim 10, wherein the power generatorincludes at least one of a ducted fan, an unducted fan, a propeller andan electric power generator.
 16. A power generating system comprising: agas turbine engine having an fluid flowpath and at least two independentturbomachinery spools; an independent turbine driving an independentcompressor on at least one of the independent spools, wherein eachcompressor compresses fluid in the flowpath; a first gearbox having apower input port coupled to the at least two independent spools and apower output port coupled to a power output shaft.
 17. The powergenerating system of claim 16, further comprising: a second gearboxhaving a power input port connected to at least one spool and a poweroutput port connected to one of the power input port of the firstgearbox and the power output port of the first gearbox.
 18. The powergenerating system of claim 16, wherein the power output shaft of thefirst gearbox is connected to at least one of a ducted fan, an unductedfan, a propeller and an electric power generator.
 19. The powergenerating system of claim 16, wherein the power input port of the firstgearbox includes connections to at least three independentturbomachinery spools.
 20. The power generating system of claim 16,wherein a power input port of the first gearbox is connected to a poweroutput port of a second gearbox and to a turbine independent of thesecond gearbox.